PDF Parts Manual JLG Gradall 522D-LoPro & 524D-LoPro Telehandler - 2 MB
Find the exact parts you need for your JLG Gradall 522D-LoPro or 524D-LoPro telehandler with this official parts manual.
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--- Page 1 ---
Illustrated Parts Manual
Models
522D LoPro
524D LoPro
S/N 0191001
P/N - 9148-4013
Revised July 6, 2007
--- Page 3 ---
INTRODUCTION
Service Kits
Starting Serial No. 0191001
Original Issue 6-01
SECTION PAGE NO. PART NUMBER DESCRIPTION
2 2-3 9141-5040 Steering Cylinder Pin Kit
5 5-1 9133-5033 Engine Filter Kit
6 6-3 9114-4382 Limited Slip Plate Stack Kit
6 6-3 9114-4383 Pinion Cage Shim Kit
6 6-3 9114-4384 Drive Pinion Shim Kit
6 6-3 9114-4385 Limited Slip Shim Kit
6 6-4 9114-4442 Brake Seal Kit
6 6-4 9114-4369 Brake Piston Plate Kit
6 6-4 9114-4370 Brake Plate & Seal Kit
6 6-4 9114-4371 Piston Brake Shim Kit
7 7-2 9114-4432 Cable Attachment Kit
7 7-2 9114-4197 Boot Kit
7 7-2 9114-4433 Heel Rest Kit
7 7-3 9114-4190 Steering Control Unit Seal Kit
7 7-3 9114-4448 Tie Strap & Boot Kit
10 10-1 9112-4071 Lift Cylinder Seal Kit
10 10-2 9108-4306 Crowd Cylinder Seal Kit
10 10-3 9108-4370 Tilt Cylinder Seal Kit
10 10-4 9103-4339 Compensating Cylinder Seal Kit
10 10-5 9108-4305 Steering Cylinder Seal Kit
10 10-6 9108-4203 Main Control Valve Stud Kit
10 10-6 9140-4178 MVC Section Seal Kit
10 10-6 9140-4179 MVC Main Relief Seal Kit
10 10-6 9108-4201 MVC Plug Seal Kit
10 10-6 9140-4180 MVC Seal Retainer Kit
10 10-6 9140-4181 MVC Spool Seal Kit
10 10-9 9108-4386 Flow Divider Valve Seal Kit
10 10-10 9108-4043 Brake Valve Repair Kit
10 10-12 9114-4459 Inching Valve Seal Kit
10 10-13 9108-4218 Main Hydraulic Pump Seal Kit
10 10-14 9108-4385 Hydrostatic Transmission Pump Seal Kit
10 10-15 9116-4109 Front Drive Motor Seal Kit
LK 1-9
--- Page 4 ---
INTRODUCTION
Part Number Index
Starting Serial No. 0191001
INDEX Original Issue 6-01
PART NUMBER PAGE PART NUMBER PAGE PART NUMBER PAGE
9114-4015 ...................................... 10-18 9114-4370 ......................................... 6-4 9114-4465 ...................................... 10-12
9114-4042 ....................................... 10-5 9114-4371 ......................................... 6-4 9114-4466 ...................................... 10-12
9114-4098 ...................................... 10-14 9114-4372 ......................................... 6-4 9114-4467 ...................................... 10-12
9114-4128 .............. 10-1, 10-3, 10-4, 10-5 9114-4373 ......................................... 6-4 9114-5128 ....................................... 13-5
9114-4158 ...................................... 10-11 9114-4374 ......................................... 6-4 9114-6052 ............................... 3-2, 13-17
9114-4190 ......................................... 7-3 9114-4376 ......................................... 6-4 9114-6053 ......................................... 4-7
9114-4191 ......................................... 7-3 9114-4377 ......................................... 6-4 9114-6054 ......................................... 4-7
9114-4192 ......................................... 7-3 9114-4378 ......................................... 6-4 9114-6058 ......................................... 5-2
9114-4197 ......................................... 7-2 9114-4379 ......................................... 6-4 9114-6081 ......................................... 2-1
9114-4326 ......................................... 6-2 9114-4380 ......................................... 6-4 9114-6099 ............................. 13-4, 13-24
9114-4327 ................................... 6-2, 6-4 9114-4381 ......................................... 6-4 9114-6101 ......................................... 5-1
9114-4328 ......................................... 6-2 9114-4382 ......................................... 6-3 9114-6102 ......................................... 7-5
9114-4329 ......................................... 6-2 9114-4383 ......................................... 6-3 9114-6108 ......................................... 7-5
9114-4332 ......................................... 6-2 9114-4384 ......................................... 6-3 9115-3031 ......................................... 5-4
9114-4333 ......................................... 6-5 9114-4385 ......................................... 6-3 9115-5016 ......................................... 5-4
9114-4334 ......................................... 6-5 9114-4386 ......................................... 6-3 9116-1210 ...................................... 10-16
9114-4335 ......................................... 6-5 9114-4387 ......................................... 6-3 9116-3012 ......................................... 7-3
9114-4336 ......................................... 6-5 9114-4388 ......................................... 6-3 9116-3028 ....................................... 12-1
9114-4337 ......................................... 6-5 9114-4389 ......................................... 6-3 9116-3044 ...................................... 10-15
9114-4338 ......................................... 6-5 9114-4390 ......................................... 6-3 9116-3087 ....................................... 12-1
9114-4339 ......................................... 6-5 9114-4391 ......................................... 6-3 9116-3093 ......................................... 7-5
9114-4340 ......................................... 6-5 9114-4392 ......................................... 6-3 9116-3098 ................................... 5-2, 9-4
9114-4341 ......................................... 6-5 9114-4393 ......................................... 6-3 9116-3109 ......................................... 7-4
9114-4342 ......................................... 6-5 9114-4394 ......................................... 6-3 9116-3121 ....................................... 13-8
9114-4343 ......................................... 6-5 9114-4395 ......................................... 6-3 9116-3129 ......................................... 5-6
9114-4344 ......................................... 6-5 9114-4396 ......................................... 6-3 9116-3130 ....................................... 12-1
9114-4345 ......................................... 6-5 9114-4397 ......................................... 6-3 9116-3184 ....................................... 12-1
9114-4346 ......................................... 6-5 9114-4398 ......................................... 6-3 9116-3191 ....................................... 13-8
9114-4347 ......................................... 6-5 9114-4399 ......................................... 6-3 9116-3201 ............................ 5-2, 9-3, 9-4
9114-4348 ......................................... 6-5 9114-4400 ......................................... 6-3 9116-3260 ......................................... 5-1
9114-4349 ......................................... 6-5 9114-4401 ......................................... 6-3 9116-3268 ......................................... 5-8
9114-4350 ......................................... 6-5 9114-4402 ......................................... 6-3 9116-4023 ....................................... 10-2
9114-4351 ......................................... 6-5 9114-4403 ......................................... 6-3 9116-4086 ......................................... 2-2
9114-4352 ......................................... 6-5 9114-4404 ......................................... 6-3 9116-4087 ......................................... 2-2
9114-4353 ......................................... 6-5 9114-4405 ......................................... 6-3 9116-4094 ................................. 2-2, 12-1
9114-4354 ......................................... 6-5 9114-4406 ......................................... 6-3 9116-4096 ....................................... 13-2
9114-4355 ......................................... 6-5 9114-4407 ......................................... 6-3 9116-4102 ....................................... 13-3
9114-4356 ......................................... 6-5 9114-4408 ......................................... 6-3 9116-4109 ...................................... 10-15
9114-4357 ......................................... 6-5 9114-4431 ......................................... 7-2 9116-4110 ...................................... 10-15
9114-4358 ......................................... 6-5 9114-4432 ......................................... 7-2 9116-4111 ...................................... 10-15
9114-4359 ......................................... 6-5 9114-4433 ......................................... 7-2 9116-6062 ......................................... 3-3
9114-4360 ......................................... 6-5 9114-4439 ......................................... 2-1 9120-4460 ....................................... 10-5
9114-4361 ......................................... 6-5 9114-4442 ......................................... 6-4 9121-3002 ................................... 8-1, 9-8
9114-4362 ......................................... 6-5 9114-4448 ......................................... 7-3 9130-1019 ......................................... 9-7
9114-4363 ......................................... 6-5 9114-4458 ......................................... 7-3 9130-1020 ......................................... 7-1
9114-4364 ......................................... 6-5 9114-4459 ...................................... 10-12 9130-1065 ...................................... 13-10
9114-4365 ......................................... 6-5 9114-4460 ...................................... 10-12 9130-1083 ......................................... 4-8
9114-4366 ......................................... 6-5 9114-4461 ...................................... 10-12 9130-1086 ......................................... 5-5
9114-4367 ......................................... 6-5 9114-4462 ...................................... 10-12 9130-3006 ......................................... 9-6
9114-4368 ......................................... 6-5 9114-4463 ...................................... 10-12 9130-3007 ......................................... 9-7
9114-4369 ......................................... 6-4 9114-4464 ...................................... 10-12 9130-3008 ......................................... 9-7
LK 1-19
--- Page 5 ---
BOOM
2 Section Boom (std)
First Boom Section
Starting Serial No. 0191001
Original Issue 6-01
Item Part No. Qty. Description Of Part
1 9108-6101 1 FIRST BOOM SECTION
2 9108-1148 1 BOOM BASE PIN
3 8820-1107 1 HEX HD CAPSCREW, 5/8-11X5
4 8852-1010 1 HEX LOCKNUT, 5/8-11
5 8820-1532 8 HEX HD CAPSCREW, 3/8-24X3/4,GR5,
(torque to 32-37 ft lbs)
8820-1533 AR HEX HD CAPSCREW, 3/8-24X7/8,GR5,
(torque to 32-37 ft lbs)
6 9002-7470 8 HARDENED FLATWASHER, 3/8
7 9103-3186 2 BEARING PAD
8 9103-1236 4 SPACER
9 9020-5870 4 SHIM
10 9103-3189 2 BEARING PAD
11 8820-1568 4 HEX HD CAPSCREW, 1/2-20X2, GR5,
(torque to 68-78 ft lbs)
8820-1569 AR HEX HD CAPSCREW, 1/2-20X2-1/4,
GR5, (torque to 68-78 ft lbs)
12 9002-7471 4 HARDENED FLATWASHER, 1/2
13 9108-3063 2 BEARING PAD
14 9108-1172 2 SPACER
15 9108-1171 2 SHIM
16 9108-3298 2 BUSHING
17 9108-1397 1 BEARING PLATE
18 8820-1607 2 HEX HD CAPSCREW, 3/4-16X1-1/4,
GR5
19 9002-7473 2 WASHER
20 8867-1001 2 LUBE FITTING, STRAIGHT, 1/8
LK 3-1
--- Page 6 ---
ATTACHMENTS
(9045-5044) 100° Swing Fork Assembly
1 Starting Serial No. 0191001
7 4 Original Issue 6-01
6 5 12 18 3 23
19 28 10 Revised 7-10-06
20 9 13 19
21 29
21
22 22 2
24
WARNING
3 8 25
11 1 14 26
15 27
16
17
30 52
43
45 41 31
36 33 32 34
35
B
42
44 41
49 35
50 30 37
2 51 46
A
47
SECTION B-B SECTION A-A
A
39 36
40 33 B
32 38
48 39
Item Part No. Qty. Description Of Part Item Part No. Qty. Description Of Part
9045-5044 1 100° SWING FORK ASSEMBLY, 31 8471-8067 2 HOSE ASSEMBLY
(includes all items) 32 9020-4097 2 HOSE ASSEMBLY
1 9104-6061 1 CARRIAGE WELDMENT 33 7713-3201 2 HOSE ASSEMBLY
2 9104-6062 1 PIVOT WELDMENT 34 8866-2084 2 ELBOW, 45 DEGREE, (includes
3 9045-3034 2 HYDRAULIC CYLINDER item 35)
4 9104-1322 2 LOCKING PLATE 35 8859-1204 6 O-RING
5 9141-1073 2 LOCKING PLATE 36 8866-2105 6 ELBOW, 90 DEGREE, (swivel nut)
6 9104-1324 2 PIVOT PIN 37 8866-2152 2 BRANCH TEE, (includes item 35)
7 9104-1325 2 PIVOT PIN 38 8866-2018 2 CONNECTOR, (includes item 39)
8 9104-1326 2 PIVOT PIN 39 8859-1205 4 O-RING
9 8320-1024 4 HEX HD CAPSCREW, 3/8-16X1, GR8 40 9104-1361 2 FITTING
10 8320-1026 4 HEX HD CAPSCREW, 1/2-13X1-1/2, 41 8866-1013 2 MALE CONNECTOR, 1/2X1/2 TUBE,
GR8 (Before S/N 2005283-01)
11 8858-1136 4 SNAP RING 8866-2006 2 CONNECTOR, (includes 8859-1205
12 8867-1022 2 LUBE FITTING, 90 DEGREE, 1/8 o-ring), (S/N 2005283-01 & After)
13 9104-1327 2 BUSHING 42 9116-3139 1 FEMALE QUICK DISCONNECT,
14 9055-1013 1 FORK PIN (Before S/N 2005283-01)
15 9020-0003 2 COLLAR 9140-3413 1 FEMALE QUICK DISCONNECT, (S/N
16 8820-1105 2 HEX HD CAPSCREW, 5/8-11X4, GR5 2005283-01 & After)
17 8852-1310 2 HEX LOCKNUT, 5/8-11 43 9116-3138 1 MALE QUICK DISCONNECT, (Before
18 9114-6053 1 LH SUPPORT BRACKET S/N 2005283-01)
19 9114-1350 2 PIN 9140-3414 1 MALE QUICK DISCONNECT, (S/N
20 9114-6054 1 RH SUPPORT BRACKET 2005283-01 & After)
21 8863-1449 2 ROLL PIN, 1/8X1-1/2 44 9104-3125 1 DUST CAP
22 9104-3221 2 DETENT PIN 45 9104-3126 1 DUST CAP
23 9104-1356 6 SPACER 46 8820-1008 2 HEX HD CAPSCREW, 1/4-20X1-3/4,
24 9015-3001 1 SERIAL NUMBER PLATE GR5
25 8834-1022 4 DRIVE SCREW, #10X3/8 47 8856-1002 2 FLAT WASHER, 1/4
26 9103-3039 2 CHAIN CONNECTION 48 9104-1362 2 ORIFICE FITTING
27 9103-3038 24" CHAIN 49 9108-3249 1 CLAMP SET
28 8867-1008 2 LUBE FITTING, STRAIGHT, 1/4-28 50 7713-3140 1 COVER PLATE
29 9114-3282 2 PINCH POINT DECAL 51 7713-3177 1 HEX HD CAPSCREW, 5/16X1-3/8
30 9104-3186 1 DOUBLE PILOT CHECK VALVE 52 8866-2106 2 ELBOW, 90 DEGREE, (swivel nut)
ER 46361, 48255, 48655, 49939 - LK * Revised parts list. 4-7
--- Page 7 ---
ENGINE & ATTACHING PARTS
(9139-5007) EPA Engine Right Side View
Starting Serial No. 0191001
Original Issue 6-01
39
37
CLT TMP 38
34
10
11 17
21
85
12 87
30
23 85 30
86
GND-10
87 86
START-C
STRT-SOL
START-C
PULL-IN
GND-10
GND-10 STRT-SOL
START-C
PULL-IN ALT BAT
STARTER
35
FWD
GND-1 STARTER RELAY
REV-B
TO ENGINE
11 GND-2
WIRE CONNECTIONS
12 14 11 ALT BAT
SNSR
GND-1 12 ALT BAT
GND-2
GND-3
34 13
BAT
GND-4 5
GND-5
GND-6
18 6
CLT TMP
GND-9
GND-10
19 7
20 8
22
39 39
16
36
ALT EXC-B
SNSR
2
3 26
4 27
1 28
9 15 29
30 24
25
33 31 26
32 27
AK 5-2
--- Page 8 ---
ENGINE & ATTACHING PARTS
Exhaust System
Starting Serial No. 0191001
Original Issue 6-01
Item Part No. Qty. Description Of Part
1 9108-3560 1 TAIL PIPE
2 8368-3175 2 MUFFLER CLAMP, (includes items
3 & 4)
3 2 BRIDGE
4 4 NUT
5 9108-3250 1 MUFFLER
6 9148-3011 1 EXHAUST PIPE
7 9116-3268 2 FLEX PIPE CLAMP
8 9148-3041 1 FLEXIBLE TUBING
9 9108-6055 1 EXHAUST TUBE
10 8319-1013 4 LOCKWASHER, M10
11 8319-1021 4 HEX HD CAPSCREW, M10X1.5X30
NOTE: ONLY ITEMS WITH PART
NUMBERS ARE AVAILABLE
FOR SERVICE.
LK 5-8
--- Page 9 ---
CONTROLS
(9138-5009) Tilt Lever Assembly
Starting Serial No. 0191001
Original Issue 3-01
Item Part No. Qty. Description Of Part
9138-5009 1 TILT LEVER ASSEMBLY, (includes items
1, 2 and 13)
1 9020-0638 1 KNOB
2 9138-6007 1 TILT LEVER WELDMENT
3 9002-8662 3 WAVE BEND WASHER
4 8856-1113 9 FLAT WASHER, 5/8
5 9108-1354 1 SHAFT
6 8863-1338 1 COTTER PIN, 3/16X1-3/4
7 8882-1004 1 YOKE END
8 8850-1406 1 HEX JAM NUT, 3/8-24
9 9002-7987 1 SPRING CLEVIS
10 9108-6081 1 ROD LINKAGE
11 9002-1552 1 CLEVIS PIN
12 9136-3036 1 HITCH PIN CLIP
13 9108-3136 2 BUSHING
14 9130-1020 1 SPACER
LK 7-1
--- Page 11 ---
HYDRAULIC CIRCUITS
Dump Circuit
Starting Serial No. 0191001
Original Issue 6-01
Item Part No. Qty. Description Of Part Item Part No. Qty. Description Of Part
1 Ref HYDRAULIC RESERVOIR, (see page 22 Ref OIL COOLER ASSY, (see page 5-5
10-16 for details) for details)
2 8866-2106 1 ELBOW, 90 DEGREE, (swivel nut) 23 Ref HOSE ASSY, (see page 9-8, item 22
3 8471-8164 1 HOSE ASSY for details)
4 8471-9071 1 HOSE ASSY 24 8866-1345 1 TUBE END REDUCER, 3/4X3/8
5 8362-3032 1 ELBOW, 90 DEGREE 25 8866-1408 1 NUT
6 8471-9109 1 HOSE ASSY 26 8866-2227 1 SWIVEL NUT BRANCH TEE, 3/4 TUBE
7 8866-1365 1 HEX CAP, 1/2 TUBE 27 8866-2239 1 SWIVEL NUT RUN TEE, 3/8 TUBE
8 8471-7839 1 HOSE ASSY 28 9105-3426 1 STRAIGHT THREAD ADAPTER,
9 8866-1364 1 HEX CAP, 3/8 TUBE (includes item 15)
10 8866-1362 1 HEX CAP, 1/4 TUBE 29 Ref FRONT DRIVE MOTOR ASSY, (see
11 9112-3149 1 DRAIN TUBE ASSY page 10-15 for details)
12 8471-7911 1 HOSE ASSY 30 7713-3053 1 CLAMP SET
13 8866-2105 1 ELBOW, 90 DEGREE, (swivel nut) 31 7713-3052 1 COVER PLATE
14 8471-6719 1 HOSE ASSY 32 8820-1010 2 HEX HD CAPSCREW, 1/4-20X2-1/4,
15 8859-1207 1 O-RING GR5
16 8866-2008 2 CONNECTOR, (includes item 17) 33 8850-1004 2 HEX NUT, 1/4-20